Fabric treatment apparatus and method

ABSTRACT

An apparatus for treatment of fabric, and including a fabric supply for supplying a length of dry fabric. A plurality of rolls having fabric-altering surface elements thereon is positioned in an upstream-to-downstream flow path for receiving the length of fabric across the surface elements thereof from an upstream fabric supply assembly to a downstream fabric take-up assembly. At least some of the plurality of rolls have drive means for positively rotating the rolls. The take-up assembly pulls the length of dry fabric off of the fabric supply assembly and through the flow path against the surface elements of the plurality of rolls in only a single pass and onto the take-up assembly.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

[0001] This invention relates to a fabric treatment apparatus andmethod. This form of treatment is generally referred to as “converting”and refers generally to processes performed on greige woven fabricsafter fabric formation to render the fabric suitable for a particularend use. Most of these processes have traditionally involved wetting andwashing the fabric in water and certain chemicals, such as acids,enzymes, surfactants, soaps and other substances to affect theappearance or feel of the fabric. In many cases, the treatment isintended to imitate natural wear and thereby give the fabric a used orworn look. The apparatus and method is particularly useful in processingfabrics made in whole or in part from natural, cellulosic fibers.

[0002] Most such converting processes require forming a long length ofwoven fabric into an endless loop, that is then cycled through theprocessing machine a specified number of times. When the fabric iswet-processed, substantial time and heat is required to dry the fabricafter processing. Drying the fabric often results in a rough, boardyfeel which must then be removed by further processing.

[0003] Through experimentation it has been determined that controlledimpact of the fabric by various shapes and edges as the fabric passesthrough an apparatus will impart surface characteristics to the fabricwithout wetting. The present invention provides a method and apparatusfor dry-processing fabric to provide a predetermined feel and surfaceappearance to the fabric. The treatment enhances the drape of the fabricand stabilizes the fabric in advance of fabrication of the fabric into aparticular end use. Such fabrics are suitable for cut-and-sew operationswhich convert the fabric into garments and household linens such assheets, pillow cases and the like. The apparatus is easily modified toalter the characteristics imparted to the fabric.

SUMMARY OF THE INVENTION

[0004] Therefore, it is an object of the invention to provide anapparatus and method for converting fabrics.

[0005] It is another object of the invention to provide an apparatus andmethod for converting fabrics by surface treatment without wetting thefabric.

[0006] It is another object of the invention to provide an apparatus andmethod for converting fabrics by surface treatment with only one pass ofthe fabric through the apparatus.

[0007] It is another object of the invention to provide an apparatus andmethod for converting fabrics by a dry surface treatment that is easilyand quickly variable to alter the characteristics of the convertedfabric.

[0008] These and other objects of the present invention are achieved inthe preferred embodiments disclosed below by providing an apparatus fortreatment of fabric, and comprising a fabric supply assembly forsupplying a length of dry fabric. A plurality of rolls havingfabric-altering surface elements thereon is positioned in anupstream-to-downstream flow path for receiving the length of fabricacross the surface elements thereof from the upstream fabric supplyassembly to a downstream fabric take-up assembly. At least some of theplurality of rolls are positively driven, and a take-up assembly pullsthe length of dry fabric off of the supply assembly and through the flowpath against the surface elements of the plurality of rolls in only asingle pass and onto the take-up assembly.

[0009] According to one preferred embodiment of the invention, thetake-up assembly includes a variable speed motor for pulling fabricthrough the apparatus at a variable predetermined constant rate.

[0010] According to another preferred embodiment of the invention, thedrive means of the rolls are reversible for rotating the rolls in eitherthe direction of movement of the fabric or in opposition to thedirection of movement of the fabric.

[0011] According to yet another preferred embodiment of the invention,the drive means are individual to each drivable roll for selectivelyrotating a roll in either the direction of movement of the fabric or inopposition to the direction of movement of the fabric without regard tothe direction of movement of any other roll.

[0012] According to yet another preferred embodiment of the invention,the fabric supply assembly includes brake remains for applying apredetermined resistance to the movement of the fabric through the flowpath to reduce wrinkling of the fabric and maintain contact between thefabric and the rolls.

[0013] According to yet another preferred embodiment of the invention,the surface elements are selected from the group consisting of grit,ribbon scrolls, spiral flutes, axially-extending edge members, chain andbuttons.

[0014] According to yet another preferred embodiment of the invention,each of the outwardly-projecting edge members defines a wavy surfaceedge.

[0015] According to yet another preferred embodiment of the invention,each of the outwardly-projecting edge members defines a wavy surfaceedge wherein the wavy surface edge of each edge member is out-of-phasewith the surface edge of any adjacent edge member.

[0016] According to yet another preferred embodiment of the invention,the edge members are paired to define a v-shape in cross-section.

[0017] According to yet another preferred embodiment of the invention,an apparatus for treatment of fabric is provided, and comprises a fabricsupply assembly for supplying a length of dry fabric and a plurality ofrolls having fabric-altering surface elements thereon positioned in anupstream-to-downstream flow path for receiving the length of dry fabricacross the surface elements from an upstream fabric supply assembly to adownstream fabric take-up assembly. The surface elements are selectedfrom the group consisting of grit, ribbon scrolls, spiral flutes,axially-extending edge members, chain and buttons. Drive means areprovided for positively rotating at least some of the plurality ofrolls. The drive means are individual to each drivable roll forselectively rotating the roll in either the direction of movement of thefabric or in opposition to the direction of movement of the fabricwithout regard to the direction of movement of any other treatment roll.The take-up assembly pulls the length of fabric off of the fabric supplyassembly and through the flow path against the surface elements of theplurality of treatment rolls in only a single pass and onto the take-upassembly.

[0018] According to yet another preferred embodiment of the invention, amethod according to the invention comprises the steps of providing aplurality of rolls having fabric-altering surface elements thereon. Therolls are positioned in an upstream-to-downstream flow path forreceiving a length of fabric across the surface elements thereof from anupstream fabric supply assembly to a downstream fabric take-up assembly.Drive means are provided for at least some of the rolls for positivelyrotating the rolls. A length of dry fabric is pulled off of the take-upassembly, through the flow path against the surface elements of theplurality of rolls in only a single pass and onto the take-up assembly.

[0019] According to yet another preferred embodiment of the invention,the step of providing drive means comprises the step of providing avariable speed motor for pulling fabric through the apparatus at avariable predetermined constant rate.

[0020] According to yet another preferred embodiment of the invention,the method includes the step of selectively rotating the rolls in eitherthe direction of movement of the fabric or in opposition to thedirection of movement of the fabric.

[0021] According to yet another preferred embodiment of the invention,the method includes the step of selectively rotating a roll in eitherthe direction of movement of the fabric or in opposition to thedirection of movement of the fabric without regard to the direction ofmovement of any other roll.

[0022] According to yet another preferred embodiment of the invention,the method includes the step of applying a predetermined resistance tothe movement of the fabric through the flow path to reduce wrinkling ofthe fabric and maintain contact between the fabric and the rolls.

[0023] According to yet another preferred embodiment of the invention,the surface elements are selected from the group consisting of grit,ribbon scrolls, spiral flutes, axially-extending edge members, chain andbuttons.

[0024] According to yet another preferred embodiment of the invention,each of the outwardly-projecting edge members defines a wavy surfaceedge.

[0025] According to yet another preferred embodiment of the invention,each of the outwardly-projecting edge members defines a wavy surfaceedge wherein the wavy surface edge of each edge member is out-of-phasewith the surface edge of any adjacent edge member.

[0026] According to yet another preferred embodiment of the invention,the edge members are paired to define a v-shape in cross-section.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Some of the objects of the invention have been set forth above.Other objects and advantages of the invention will appear as theinvention proceeds when taken in conjunction with the followingdrawings, in which:

[0028]FIG. 1 is a flow diagram of a fabric treating apparatus accordingto an embodiment of the invention;

[0029]FIG. 2 is a flow diagram of the fabric treating apparatusaccording to FIG. 1, and set up for processing a light cotton upholsteryfabric;

[0030]FIG. 3 is a flow diagram of the fabric treating apparatusaccording to FIG. 1, and set up for processing a denim fabric;

[0031]FIG. 4 is a schematic representation of a roll having ribbonscroll elements thereon;

[0032]FIG. 5 is a schematic representation of a roll having spiralflutes thereon;

[0033]FIG. 6 is a schematic representation of a roll having outwardlyprojecting blades with wavy edges thereon;

[0034]FIG. 7 is a schematic representation of a roll having chainthereon;

[0035]FIG. 8 is a schematic representation of a roll having brassbuttons thereon; and

[0036]FIG. 9 is a schematic representation of a roll having gritthereon.

DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

[0037] Referring now specifically to the drawings, a fabric treatingapparatus according to the present invention is illustrated in FIGS. 1,2 and 3, and shown generally at reference numeral 10. The fabrictreating apparatus 10 comprises a frame 11 which mounts rolls acrosswhich fabric to be processed is passed, as described below. The frame 11according to one embodiment of the invention is 8 ft. wide and acceptsrolls which will accommodate and process fabric up to 84 in. wide. Otherwidths are, of course, possible.

[0038] A roll of fabric “F” is mounted on a supply mandrel 12 and fedthrough top and bottom supply rolls 13 and 14. The fabric 11 is fed inopen width and is generally sewn to a piece of waste fabric that is usedto feed the fabric “F” into the apparatus 10 and to establish properrunning conditions before the actual fabric treatment process begins.The fabric “F” is processed in dry form. As used herein, “dry” means afabric which contains only ambient humidity or only such additionalhumidity as is necessary to optimize processing without the necessity ofa subsequent drying process, as would be necessary by saturating thefabric with water.

[0039] Preferably, the top roll 13 includes a brake assembly 15 whichimparts drag to the supply rolls 13, 14. By retarding rotation of thesupply rolls 13, 14, tension sufficient to prevent or reduce wrinklingand insure contact between the fabric and the treatment rolls isprovided. The brake assembly 15 may be a drum brake powered by apneumatic pressure actuator.

[0040] At least one of the supply rolls 13, 14 is covered with grit toreduce lateral movement of the fabric “F” and consequent wrinkling orskewing as the fabric “F” is fed downstream.

[0041] Idler rolls 18, 19, 20 and 21 define the generalupstream-to-downstream flow path of the fabric. These idler rolls havepolished surfaces and position the fabric to be properly fed totreatment rolls 25, 26, 27 and 28.

[0042] Treatment rolls 25, 26, 27 and 28 are carried for rotation byframe 11 in suitable bearings and are preferably driven by individualdrive motors 25A, 26A, 27A and 28A. Alternatively, some or all of therolls 25, 26, 27 and 28 can be driven through chain or gear drives froma single or multiple motors. Motors 25A, 26A, 27A and 28A are variablespeed, reversing direction motors.

[0043] As described below, each of the rolls 25, 26, 27 and 28 areprovided with predetermined surface treatment elements based on thefinish to be applied to the fabric surface. Fabric treatment may takeplace by passing the fabric over one, less than all, or all of thetreatment rolls 25, 26, 27 and 28. Likewise, the rolls 25, 26, 27 and/or28 may be changed to alter the type of surface treatment elements or tovary the order in which the fabric engages a particular surfacetreatment element.

[0044] The processed fabric “F” may be rolled onto a take-up roll 30 bya pair of feed rolls 31, 32 driven by a motor 33. Motor 33 is preferablya 2.5 HP motor connected to a variable speed drive which permits thefabric “F” to be fed at varying rates of between approximately 3-30yd/min. Alternatively, the fabric “F” may be fed by the feed rolls 31,32 into a container for later retrieval. The apparatus 10 and associatedmethod differ from many systems whereby the fabric must be formed into aloop and passed multiple times through the processing areas of theequipment.

[0045] Referring now to FIGS. 4-8, the surface elements carried by thetreatment rolls 25-28 are illustrated. For purposes of illustrationonly, the surface elements are shown in a particular arrangement.However, the order of the surface elements in the flow path may vary,some surface elements may not be used with particular fabrics, and somesurface elements may be used on multiple rolls.

[0046]FIG. 4 illustrates the roll 25 that is covered with ribbon scrollwire 40 that is spiraled in spaced-apart relation around the surface ofthe roll 25. The wire 40 is spiraled symmetrically from the center toopposite ends of roll 25 with the spiral in the direction whereby thefabric is maintained in a taut condition by the movement of the spiraledwire 40 as it passes over the roll 25. The diameter of the wire 40 andthe spacing between adjacent wraps may be vary, a typical diameter being⅛ in. with 1 in. spacings between adjacent wraps. The surface of thewire 40 is relatively smooth, and the principal function of this roll isto maintain the fabric “F” at its full width without wrinkles orskewing.

[0047]FIG. 5 illustrates a spiraled high rib flute 41 welded to thesurface of the treatment roll 26. The flute 41 is spiraled symmetricallyfrom the center to opposite ends of roll 26 with the spiral in thedirection whereby the fabric is maintained in a taut condition by themovement of the spiraled flute 41 as it passes over the roll 26. Thepitch of the spiral is such that the flutes will exert a lateralbrushing motion to the surface of the fabric “F” which begins theprocess of softening and breaking the stiffness of the fabric “F.” Thespacing between adjacent wraps of the flute 41 may be vary, a typicalspacing being approximately 4 in. between adjacent wraps.

[0048] Referring now to FIG. 6, roll 27 is provided with four pairs ofblades 42 which extend outwardly in a v-shaped configuration laterallyalong the length of roll 27. These blades may be straight or, as shown,provided with a undulating outer edge which appears wavy and which willthus engage the fabric “F” with different force at different positionsalong its width. The undulations in the blades 42 are offset relative toeach other so that all of the blades 42 do not engage the fabric withthe same impact at the same position along the width of the fabric. Thisprovides a randomized abrading treatment to the surface of the fabricwhich assists in breaking down the starch component of the fibers andthus contributes to a desirable softening of the fabric “F.”

[0049] Referring now to FIG. 7, roll 28 is covered with a length ofchain 44 welded to the surface in a spiral configuration. The chain 44is spiraled symmetrically from the center to opposite ends of roll 28with the spiral in the direction whereby the fabric is maintained in ataut condition by the movement of the spiraled chain 44 as it passesover the roll 28. The size and type of chain can vary widely dependingon the desired effect to be achieved, and the spacing between adjacentwraps may vary, a typical spacing between adjacent wraps being 2 in. Thesurfaces of the chain 44 are of varying heights and orientationsrelative to the roll 28 and the direction of travel of the fabric “F”,and thereby imparts vigorous, random impacts to the fabric “F” as itpasses over the roll 28.

[0050] Referring now to FIG. 8, a roll 50 is shown and illustratesanother type of surface treatment element which may be used in theapparatus 10 in place of or along with rolls of the type discussedabove. Roll 50 is covered with an array of raised brass buttons 51,which, for example, are ⅝ in. in diameter and extend upwardly ⅜ in.above the adjacent surface of the roll 50. Alternatively, buttons ofdiffering diameters and heights may be applied.

[0051] As noted above, either roll 13 or 14, roll 13 shown in FIG. 9, iscovered with a sheet having grit 47 adhered thereto. However, a rollhaving grit on the surface may be used in place of one or more of therolls 25, 26, 27, 28 to give the surface of the fabric “F” a napped or“sanded” look.

[0052] Referring again to FIGS. 1, 2 and 3, each of the rolls 25, 26,27, and 28, being driven by variable speed, reversing motors 25A, 26A,27A, and 28A, may be driven at a surface speed different from the rateof travel of fabric “F” through the apparatus 10, and in an oppositedirection. This enables substantially different relative rates ofmovement between the fabric “F” and the various surfaces on the rolls25, 26, 27, and 28.

[0053]FIG. 2 illustrates the apparatus 10 configured to process a lightcotton upholstery fabric. Fabric “F” is pulled by the take-up rolls 31,32 off of the supply roll positioned on supply mandrel 12. The fabric ispassed behind idler roll 18 and against treatment roller 25, that is setup to rotate in the opposite direction to the direction of travel of thefabric “F.” The fabric “F” then passes under idler roller 19, overtreatment roller 26, under idler roller 20, over treatment roller 27,under treatment roller 28, past idler roller 21 and then through thetake-up rollers 31, 32.

[0054] The treatment rollers 26, 27 and 28 rotate in the same directionof travel as the fabric “F”, and are driven by respective motors 26A,27A, and 28A at a surface speed different from the rate of travel of thefabric “F”, thus providing a surface treatment to the fabric “F.” Thefabric “F” is passed through the apparatus 10 only once, and either theface or reverse side of the fabric “F” may be oriented directly againstthe treatment rollers 25, 26 27 and 28. Alternatively, the fabric “F”may be passed through the apparatus 10 with both sides being engaged bydifferent ones of the rollers 25, 26 27 and 28. In each case, therollers 25, 26, 27 and 28 are configured as illustrated and describedwith reference to FIGS. 4, 5, 6 and 7.

[0055]FIG. 3 illustrates the apparatus 10 configured to process a denimfabric “F”. Fabric “F” is pulled by the take-up rolls 31, 32 off of thesupply roll positioned on supply mandrel 12. The fabric “F” is passedbehind idler roll 18 and against treatment roller 25, that is set up torotate in the opposite direction to the direction of travel of thefabric “F.” The fabric “F” then passes under idler roller 19, overtreatment roller 26, under idler roller 20, over treatment roller 27,under idler roller 21 and then through the take-up rollers 31, 32.

[0056] The treatment rollers 26 and 27 rotate in the same direction oftravel as the fabric “F”, and are driven by respective motors 26A and27A at a surface speed different from the rate of travel of the fabric“F”, thus providing a surface treatment to the fabric “F.” The fabric“F” is passed through the apparatus 10 only once, and either the face orreverse side of the fabric “F” may be oriented directly against thetreatment rollers 25, 26 and 27.

[0057] A fabric treating apparatus is described above. Various detailsof the invention may be changed without departing from its scope.Furthermore, the foregoing description of the preferred embodiment ofthe invention and the best mode for practicing the invention areprovided for the purpose of illustration only and not for the purpose oflimitation—the invention being defined by the claims.

We claim:
 1. An apparatus for treatment of fabric, and comprising: (a)an upstream fabric supply assembly for supplying a length of dry fabric;(b) a plurality of rolls having fabric-altering surface elements thereonpositioned in an upstream-to-downstream flow path for receiving thelength of fabric across the surface elements thereof from the fabricsupply assembly, at least some of the plurality of rolls having drivemeans for positively rotating the rolls; and (c) a take-up assembly forpulling the length of dry fabric off of the fabric supply assembly andthrough the flow path against the surface elements of the plurality ofrolls in only a single pass and onto the take-up assembly.
 2. Anapparatus according to claim 1, wherein said take-up assembly includes avariable speed motor for pulling fabric through the apparatus at avariable predetermined constant rate.
 3. An apparatus according to claim1, wherein the drive means of the rolls are reversible for rotating therolls in either the direction of movement of the fabric or in oppositionto the direction of movement of the fabric.
 4. An apparatus according toclaim 1, wherein said drive means are individual to each drivable rollfor selectively rotating a roll in either the direction of movement ofthe fabric or in opposition to the direction of movement of the fabricindependent of the direction of movement of any other roll.
 5. Anapparatus according to claim 1, wherein said fabric supply assemblyincludes brake means for applying a predetermined resistance to themovement of the fabric through the flow path to reduce wrinkling of thefabric and maintain contact between the fabric and the rolls.
 6. Anapparatus according to claim 1, wherein said surface elements areselected from the group consisting of grit, ribbon scrolls, spiralflutes, axially-extending edge members, chain and buttons.
 7. Anapparatus according to claim 6, wherein each said outwardly-projectingedge member defines a wavy surface edge.
 8. An apparatus according toclaim 6, wherein each said outwardly-projecting edge member defines awavy surface edge wherein the wavy surface edge of each edge member isout-of-phase with the surface edge of any adjacent edge member.
 9. Anapparatus according to claim 6, wherein said edge members are paired todefine a v-shape in cross-section.
 10. An apparatus for treatment offabric, comprising: (a) an upstream fabric supply assembly for supplyinga length of dry fabric; (b) a plurality of rolls having fabric-alteringsurface elements thereon positioned in an upstream-to-downstream flowpath for receiving the length of dry fabric across the surface elementsfrom the fabric supply assembly; (c) the surface elements selected fromthe group consisting of grit, ribbon scrolls, spiral flutes,axially-extending edge members, chain and buttons; (d) drive means forpositively rotating at least some of the plurality of the rolls, thedrive means being individual to each drivable roll for selectivelyrotating the roll in either the direction of movement of the fabric orin opposition to the direction of movement of the fabric withoutindependent of the direction of movement of any other roll; and (e) atake-up assembly for pulling the length of fabric off of the fabricsupply assembly and through the flow path against the surface elementsof the plurality of rolls in only a single pass and onto the take-upassembly.
 11. A method of treating fabric, and comprising the steps of:(a) providing a plurality of rolls having fabric-altering surfaceelements thereon and positioned in an upstream-to-downstream flow pathfor receiving a length of fabric across the surface elements thereoffrom an upstream fabric supply assembly to a downstream fabric take-upassembly; (b) providing drive means for at least some of the rolls forpositively rotating the rolls; and (c) pulling a length of dry fabricoff of the fabric supply assembly, through the flow path against thesurface elements of the plurality of rolls in only a single pass andonto the take-up assembly.
 12. A method according to claim 11, whereinthe step of providing drive means comprises the step of providing avariable speed motor for pulling fabric at a variable predeterminedconstant rate.
 13. A method according to claim 11, and including thestep of selectively rotating the rolls in either the direction ofmovement of the fabric or in opposition to the direction of movement ofthe fabric.
 14. A method according to claim 11, and including the stepof selectively rotating a roll in either the direction of movement ofthe fabric or in opposition to the direction of movement of the fabricindependent of the direction of movement of any other roll.
 15. A methodaccording to claim 11, and including the step of applying apredetermined resistance to the movement of the fabric through the flowpath to reduce wrinkling of the fabric and maintain contact between thefabric and the rolls.
 16. A method according to claim 11, wherein saidsurface elements are selected from the group consisting of grit, ribbonscrolls, spiral flutes, axially-extending edge members, chain andbuttons.
 17. A method according to claim 16, wherein each saidoutwardly-projecting edge member defines a wavy surface edge.
 18. Amethod according to claim 16, wherein each said outwardly-projectingedge member defines a wavy surface edge wherein the wavy surface edge ofeach edge member is out-of-phase with the surface edge of any adjacentedge member.
 19. A method according to claim 16, 17 or 18, wherein saidedge members comprise are paired to define a v-shape in cross-section.